Method For Producing an Electronic Object Comprising a Data Transfer Stage and the Obtained Object

ABSTRACT

A method for producing a portable electronic object having contact pads arranged on a plane with a thickness which differs from the thickness of a standard smartcard. The object is electrically connected to data transfer station connectors, by delivering a data transfer station having an electric probe connector and submitting the object to the data transfer station in such a way that the contact pads thereof are accessible to the electric probes in a direction perpendicular to the plane. Objects obtainable include UBS keys or PCMCIA cards or readers.

The invention relates to a method for producing a portable electronicobject comprising contact pads and having a thickness which differs fromthat of a standard smart card, as well as to the obtained objects.

More specifically, the method comprises a step of electricalpersonalisation and/or initialisation of the object or electrical datatransfer.

It has a preferable application in the production of personalised USBkey drives, but can also be applied to other objects of variousthicknesses having electrical contacts, such as memory cards, inparticular such as MMC (multimedia cards), SD and PCMCIA-type cards orreaders.

The USB keys are designed to be connected to a USB peripheral port(acronym for Universal Serial Bus) of a telecommunications device suchas a personal computer. In general terms, a USB key comprises oneportion inserted in the port of the device and another portion remainingoutside the port for handling purposes. The key generally comprises ametal band surrounding the contacts.

The scope of use is as vast as that of smart cards and/or card readers(data securitisation, internet access, identification, e-commerce,on-line payment, cryptography, etc.)

Patent application PCT/FR02/03247 describes a method of producing a USBelectronic key in which a module having contact pads compatible with theUSB format is cut out from a smart card, and its thickness is thenadjusted, at least at the level of the contact pads, to have a thicknessthat conforms to the USB standard. No electrical personalisation and/orinitialisation is mentioned after the key has a thickness greater thanthat of a smart card.

The electrical personalisation and/or initialisation of USB keys isperformed by manual insertion in a suitable connector. These operationsconsist of loading data which may be required for the operation of anobject (data, program, encryption key) in the memory thereof by means ofelectrical contacts. In other cases, the operation can also consist ofpre-loading multimedia data.

It can also consist of an electrical or electronic test operation of acircuit of the object, with or without electronic memory.

These operations are henceforth considered capable of being performedusing a data-transfer station.

The invention aims to solve these disadvantages. It has the main aim ofallowing automatic, high-speed data transfers (test, initialisation,electrical personalisation, loading, etc.) by electrical contact on aportable electronic object.

It also aims to facilitate the production operations of these objects.

For this purpose, the invention relates to a method of producing aportable electronic object, said method comprising the following steps:

-   -   supplying an object comprising contact pads on one plane,    -   supplying a data-transfer station having at least one connector        with electric probes and having means for automatically gripping        the object,    -   automatic electric connection of the contact pads of the object        with the connector of the data-transfer station,    -   presenting the object to the data-transfer station so that the        contact pads of the object can be accessed directly by the        electric probes of the connector in a direction perpendicular to        the plane.

The method is characterised in that the object has a thickness whichdiffers from that of a standard smart card,

and in that said means for automatically gripping the object are capableof adapting to an object thickness which differs from that of a standardsmart card.

According to one embodiment, the object is provisionally attached to asupport body by means of attachment means.

In this way, thanks to the invention, it is possible to personalise andproduce electronic products that have thicknesses which differ entirelyfrom that of a smart card using a card support with a surface area thatis preferably substantially equal to that of a smart card in order touse current machines.

According to one specific embodiment:

-   -   the method comprises a prior step in which the object is        configured so that the electrical contacts open onto the surface        through at least one window made in one face of the object;

In this way, it is even possible to use current smart-card machines toproduce electronic objects not initially designed for this purpose, forexample because they have an original thickness which is much greaterthan that of a smart card and/or connectors with different access forms.

According to other embodiments:

-   -   the card body is in the ISO smart-card format;    -   the object is chosen from among a USB key, an MMC card, an        auxiliary storage card, any card comprising electrical contacts        on the surface and having a thickness of more than 1 mm.

According to a preferred embodiment, the object is a USB key comprisinga handling body and a connector extending as an extension of the body,said connector comprising a band surrounding linear contact pads.

It is characterised in that the windows in the band are dimensioned sothat the electrical personalisation and/or initialisation can beperformed through said openings of said band.

According to other embodiments:

-   -   the band comprises at least one window for accessing the        contacts, extending transversally across all the contacts;    -   the attachment means comprise a pressure-sensitive adhesive        fixed to the support card body;    -   the attachment means comprise strips for linking with the card        body having a predetermined break-off line;    -   the object is fixed to the strips so as to be entirely        positioned above the general plane of the card plane;    -   an initial part of the object is attached to the card body and a        production operation is performed while such part remains        attached to the card body, said operation being chosen from        among an operation of assembling complementary parts of the        object with the initial part, graphic printing, packaging;    -   the initial part of the object is produced at the same time as        the card body by injection moulding and the complementary parts        are assembled, the initial part being detachable from the card        body;    -   the initial part can be detached from the card body by breaking        a predetermined break-off line around the object;    -   the initial part is chosen from among a bottom shell, a top        shell, an integrated-circuit support body and/or an        integrated-circuit module.

The invention also relates to the product resulting from the abovemethod.

In particular, it relates to a portable object with electronic memorycomprising contact pads, said object being attached with the help ofprovisional attachment means to a support card and comprising contactpads which can be accessed in a direction perpendicular to the plane ofthe card body.

The object is characterised in that it has a thickness that is greateror smaller than that of the support card.

According to one embodiment, the object is configured to ensure that allthe contacts open onto the surface by means of at least one window madein one face of the object. At least the contact pads required for a datatransfer must be arranged in this way.

According to a specific embodiment, the invention relates to a portableelectronic object having at least one face and contact pads, tracks orelectrical connectors arranged under this face, said object comprising aso-called main opening allowing the contact pads or main connectors tobe accessed through this opening in a direction (J),

characterised in that it comprises at least one window made in said faceso as to make the contact pads, tracks or main electrical connectorsused for electric transfer accessible through the window in a directionother than the direction (J).

Other special features and advantages of the invention will becomeapparent from reading the description made as a strictly non-limitingexample in relation to the appended figures, in which:

FIG. 1 shows a connector of a terminal designed to receive a USB key;

FIG. 2 shows a partial top view of a USB key showing a metal band;

FIG. 3 shows a front view of the electrical personalisation and/orinitialisation step diagrammatically depicting the electric probes;

FIGS. 4, 4 a respectively show a front view of a band and a partial topview of a USB key showing a metal band according to a first embodimentof the invention;

FIGS. 5, 5 a respectively show a front view and a partial top view of aUSB key showing a metal band according to a second embodiment of theinvention;

FIG. 6 shows a key obtained by the assembly method of FIG. 7;

FIG. 7 shows an exploded perspective view of the components of a keyaccording to the invention in the process of assembly according to apreferred embodiment;

FIG. 8 shows a display unit for keys obtained according to theinvention;

FIG. 9 shows a PCMCIA-type object configured according to one embodimentof the invention.

The production method according to the invention relates to portableobjects with electronic memory which comprise contact pads and whichhave a thickness which differs from that of a standard smart card. Inparticular according to ISO 7816, this thickness is equal to around 0.76mm.

Preferably, the thickness of these objects is markedly greater than 0.76mm, for example 1 mm and, in particular, around 3-7 mm for a USB key;however, the invention does not exclude objects that are much thinnerthan 0.76 mm, for example thinner than 0.4 mm, as long as there is aconsiderable difference, for example more than 0.5 mm with the thicknessof a standard smart-card body, which is 0.76 mm.

It excludes modules (dielectric associated with contact pads connectedto a resin-coated chip) designed to be permanently inserted in a cardbody cavity. In fact, modules to be inserted particularly using apermanent adhesive are not electronic entities as such when usedindependently from the card body.

The object can be chosen from among a USB key, an MMC card, an auxiliarystorage card, any card comprising electrical contacts on the surface andhaving a thickness as above.

It is known to personalise objects with electronic memory, such as smartcards with mini-SIM chips which are detached from the card body onceelectrically personalised, but problems arise with objects that havedifferent thicknesses and are furthermore generally produced accordingto various methods other than those used to obtain smart cards.

According to the invention, the method comprises a step of electricalpersonalisation and/or initialisation of the object and/or datatransfer.

In reference to FIGS. 1 and 2, this step consists in the prior art, inparticular for a USB key 1, of connecting the key to a connector 3 of apersonalisation terminal/station. This operation is performed manuallyand then all kinds of data, programs, secret keys or others can beinserted in the object via this interface by the connectors 4.

USB keys of the prior art comprise a band 2 surrounding the contact pads12 as an extension of the handling body 2B.

The band comprises windows 2C in order to allow a first originalfunction, which is to engage the supporting leaf springs 3A, 3C of theconnector in FIG. 1.

According to one characteristic of implementation of the invention, theobject is initially attached to a support body 6 using attachment meansand then presented to a personalisation and/or initialisation 10 ortransfer station which is completely different from the prior art asindicated below.

In the example, in FIG. 3, the object in this case is a USB key 5, andthe support body 6 is advantageously in the format of a smart card, madefrom PVC plastic.

Other formats or thicknesses may be used, and the body can be made fromanother plastic material, but may also be made from a differentmaterial, for example cardboard, paper, metal or others.

According to another characteristic, the object is attached usingprovisional attachment means (allowing the object to be detached) so asto make its contact pads accessible to a connector with rectilinearprobes in a direction perpendicular to the plane of the card body.

In the example, the key is attached with the help of three studs 7solidly attached to the card. They comprise notches 8 cooperating withthe corners of the handling body 9 to hold the key on the support body6.

The studs advantageously slightly exceed the total thickness of the keyin order to provide a base plane for another card to be stacked, thusallowing stable and regular stacking despite the bulging shapes of thekeys.

As an alternative, the attachment means 7, 8 can comprise apressure-sensitive adhesive (not shown) fixed to the support card body.They can also comprise strips for linking 17 to the card body 6B andhave a predetermined break-off line or pre-cut 18 surrounding the key asexplained in a preferred example below.

The attachment means can cooperate with shapes of the object forsupporting it, for example an angular contour 9A on the handling body.

According to another characteristic of implementation, thepersonalisation and/or initialisation 10 is performed by means ofrectilinear electric probes 11, represented by four arrows in thefigure. These probes have a geometrical configuration that is adapted tothe configuration of the electrical contact pads of the USB key andsimply need to rest perpendicularly against the contact pads 12.

The inventors have realised that automatic electrical personalisationstations 10 comprise gripping means, generally used to grip an ISOformat smart card and move it to different work stations, but which havea design that offers considerable tolerance as regards the thickness ofthe card. This tolerance can be of several millimetres, currently up to15 mm. This station can therefore adapt to objects with differentthicknesses and shapes thanks to these gripping means, possibly withadjustable or variable gripping openings.

The card gripper in fact has a gripping and support mechanism comparablewith a clothes peg, with a considerable opening. Other mechanisms can beused, such as a system with a jack pressing on the object.

The personalisation installation comprises means for moving andpositioning the key with its support in the gripping means with a claw,which grip and support the assembly for handling between operationstations.

Advantageously, the installation can comprise several gripping means andan electrical transfer station for each gripping means, for examplemounted forming a cylinder. In this way, the electrical transfer iscarried out in concurrent operation time during the movement of theobject within the production chain.

This implementation is relatively straightforward for objects thatalready have contact surface opening onto the surface. However, in thecase of a USB key with a metal band, the contacts are not always easilyaccessible.

This is why the method also comprises an alternative embodiment in whicha prior step consists of configuring the object so that the electricalcontacts open onto the surface through at least one window made in oneface of the object.

In FIG. 4, the face in question is a metal band 13 surrounding linearcontact pads 12 of the connector, and which extends as an extension ofthe key handling body 9.

Prior to complete assembly of the key, a band specific to the embodimentof the invention is created, by arranging and dimensioning at least oneopening or window 14 in the band 13 in order to allow electricalpersonalisation and/or initialisation through said openings.

In one example, FIGS. 4 and 4 a, a single window 14 for accessing thecontacts extends transversally across all the contacts. Its dimensionsare, for example, 9.7×2 mm. In another example, FIG. 5, 5 a, two windows15 with respective dimensions equal to 3.5×2 mm are arranged in the band16 allowing free access to the contact pads.

The windows can be designed to also allow their first original function,which is to engage the supporting leaf springs 3A, 3C of a connectorsuch as that shown in FIG. 1.

In FIG. 6, the USB key 5 is fixed to strips 17 which are in turnconnected to the support body 6B so as to be entirely positioned abovethe general plane of the card plane or at least above a bottom plane 19of the support body 6B.

This allows the cards to be stacked with mutual self centering.

In reference to FIG. 7, a preferred embodiment of the invention will nowbe described for obtaining the key depicted in FIG. 6.

According to a first step of this embodiment, an initial part 20 of theobject 5 is fixed to a card body 6B and a production operation mentionedbelow is performed while the object remains attached to the card body.

These operations can include an operation of assembling complementaryparts 21, 22 of the object with the initial part, graphic printing 23,packaging. For graphic printing, it is possible in particular to performink-jet printing.

In this way, rather than attaching the finished object directly to thecard, in particular using the previously indicated attachment means 7,one element 20 is attached to the object and then completed with theremaining elements 21, 22, 13.

In the example, a bottom shell 20 of the key is attached by strips 17 toa card body.

According to one advantageous step, the initial part of the object isproduced at the same time as the card body by injection moulding and thecomplementary parts are assembled, the initial part being detachablefrom the card body. Where applicable, the pre-cut can be mademechanically, for example by punching.

In the example, the initial part is the bottom shell of the key, but itis foreseeable to choose another part such as the top shell 22 or asupport body 21 of an integrated circuit 23 or of an integrated-circuitmodule.

The initial part can preferably be detached from the card body bybreaking a predetermined break-off line around the object.

In the example, this line is formed by a recess 18 surrounding the shelland by thinner areas of the strips at the edges of the bottom shell. Thestrips support the shell at a level situated completely above thegeneral top plane 24 of the card.

The assembly of the key is depicted by the steps of assembly in theorder of the arrows (A, B, C).

In particular, a bottom shell is assembled comprising two essentialparts: a concave part 20 providing a space 25 for receiving a part 21 ofa support and a flat area 26 or plate extending the concave part.

After assembly, the chip support 21 rests entirely against the bottomshell and the flat area extends entirely under a front part of thesupport comprising the contact pads 12.

The flat area has the function of completing the thickness of thesupport at the level of the contact pads so as to have an overallthickness at this level that conforms to the USB standard.

The chip support has a thickness of around 0.76 mm while the USBthickness to be reached is around 1.95 mm.

The support can comprise, on its bottom face, a transversal groove 27 aadjacent to the module. It has the function of becoming accommodated ona matching rib 27 b of the case located at the junction of the twosub-parts 25/26 of the bottom shell and locking the support 21 inposition.

Other attachment means, detachable or not, in particular by gluing,clipping or sliding known to those skilled in the trade for holding thesupport in place in the shell can complete the shell and/or the support.

The key can thus be used, where applicable, with a metal band 13surrounding the whole of the flat area and the contact pads of thesupport 21.

A top half-shell 22 is placed above the support so as to cover a part ofthe support, in this case the rear part of the support, outside thecontact pads, and to be fitted onto the bottom shell, sandwiching thechip support 21.

The top half-shell can comprise a shoulder 28 with the same width as themetal band, and which extends towards the front of the shell. Theshoulder can extend, for example, to the limit of the contact pads afterassembly on the support. The metal band or ring 13 can thensurround/circle the entire flat area, shoulder and contacts in order toprovide additional support for the two top and bottom half-shells.

The top half-shell can be inserted, using any suitable attachment means,on the bottom half-shell.

The shells can be assembled by snap-fitting, gluing, ultrasonic sealing,screwing, etc.

Finally, to complete the key, the front part of the shell can comprisemeans for attaching a protective cap.

The card body can comprise an orifice 29 (FIG. 6) for hanging the keysor objects resulting from the method.

FIG. 8 shows display units 30 comprising the object 5 of the inventionwithout any other packaging than that provided by the support card.Where applicable, an additional wrapping, such as a transparent plasticfilm, is affixed on either side of the key.

Thanks to the invention, the same support 6B is used at least forelectrical personalisation, data transfer and for packaging purposes,while neither the initial thickness of the card support nor its originallow it to be compared with an object produced otherwise and having adifferent thickness.

In FIG. 9, a portable electronic object comprises at least one face 35and electrical tracks 36 arranged under this face. These electricaltracks make is possible to test, initialise, personalise and charge theelectronic circuit of the object.

The tracks can be contact pads or electric connectors. In the example,these are electrical tracks arranged on a printed circuit 37 of theobject. In fact, the opening is arranged above the passage of theconductors used when performing an electrical transfer.

According to one embodiment, the object comprises a window made in theface so as to provide access to the tracks through said window in afirst direction F.

The object can comprise a second so-called main window designed toprovide access to the contact pads or connectors 37 through the secondwindow in a direction J which differs from the first direction F. Theaforementioned electrical data or signal transfers are generally carriedout via these connectors 37.

In the example, the object depicts a PCMCIA card 39 seen from below.Since its format is substantially equal to that of a smart card (withthe exception of its thickness), it does not require a support card inorder to be personalised, tested, etc.

The object can also act as a smart-card reader by comprising asmart-card connector placed, for example, on the face opposite the face35.

According to another embodiment, the PCMCIA card can comprise openingsor windows 40 arranged on one face near the main connector 37.

In this case, the main connectors are accessible in a direction F′ whichdiffers from and is more practical than the direction J for automatedpersonalisation.

1. Method of producing a portable electronic object, said methodcomprising the following steps: supplying an object comprising contactpads on one plane, supplying a data-transfer station having at least oneconnector with electric probes and having means for automaticallygripping the object, automatic electric connection of the contact padsof the object with the connector of the data-transfer station,presenting the object to the data-transfer station so that the contactpads of the object can be accessed directly by the electric probes ofthe connector in a direction perpendicular to the plane, wherein theobject has a thickness which differs from that of a standard smart card,and said means for automatically gripping the object are capable ofadapting to an object thickness which differs from that of a standardsmart card.
 2. Method according to claim 1, wherein the object isprovisionally attached to a support body by means of attachment means.3. Method according to claim 2, wherein it comprises a prior step inwhich the object is configured so that the electrical contacts open ontothe surface through at least one window made in one face of the object.4. Method according to claim 1, wherein the card body is in ISOsmart-card format (54 mm×85 mm).
 5. Method according to claim 1, whereinthe object is chosen from among a USB key, an MMC card, an auxiliarystorage card, any card comprising electrical contacts on the surface andhaving a thickness of more than 1 mm.
 6. Method according to claim 3,wherein the object is a USB key comprising a handling body and aconnector extending as an extension of the body, said connectorcomprising a band surrounding the linear contact pads, wherein: at leastone window is dimensioned in the band so that the data transfer can beperformed through said window.
 7. Method according to claim 6, whereinthe band comprises at least one window for accessing the contacts,extending transversally across all the contacts.
 8. Method according toclaim 2, wherein the provisional attachment means comprise apressure-sensitive adhesive fixed to the support card body.
 9. Methodaccording to claim 1, wherein the attachment means comprise studs withnotches extending perpendicularly to the surface of the support cardbody.
 10. Method according to claim 1, wherein the attachment meanscomprise strips for linking to the support card body having a pre-cut ora predetermined break-off line.
 11. Method according to claim 10,wherein the object is attached to the strips so as to be entirelypositioned above the top plane of the support card.
 12. Method accordingto claim 1, wherein an initial part of the object is attached to thecard body and a production operation is performed while the initial partremains attached to the card body, said operation being chosen fromamong an operation of assembling complementary parts of the object withthe initial part, graphic printing, and packaging.
 13. Method accordingto claim 12, wherein the initial part of the object is produced at thesame time as the card body by injection moulding and the complementaryparts are assembled, the initial part being detachable from the cardbody.
 14. Method according to claim 12, wherein the initial part can bedetached from the card body by breaking a predetermined break-off linearound the object.
 15. Method according to claim 12, wherein the initialpart is chosen from among a bottom shell a top shell, anintegrated-circuit support body and/or an integrated-circuit module. 16.Portable electronic object comprising contact pads in one plane whichcan be accessed in a direction perpendicular to the plane, said objectbeing attached by means of provisional attachment means to a supportcard, wherein the object has a thickness that is greater or smaller thanthat of the support card.
 17. Object according to claim 16, wherein itis configured to ensure that all the electrical contacts open onto thesurface by means of at least one window made in one face of the object.18. Object according to claim 16, wherein the support card is in ISOsmart-card format.
 19. Object according to claim 16, wherein itconstitutes a USB key, an MMC card, an auxiliary storage card, or anycard comprising electrical contacts on the surface and having athickness of more than 1 mm.
 20. Object according to claim 16, whereinthe object is a USB key comprising a handling body and a connectorextending as an extension of the body, said connector comprising a bandsurrounding the linear contact pads and comprising at least one windowon one face of the band, wherein: the window is dimensioned so as to belocated facing all the contact pads.
 21. Object according to claim 20,wherein the band comprises at least one window for accessing thecontacts, extending transversally across all the contacts.
 22. Objectaccording to claim 16, wherein the object is attached with the help of apressure-sensitive adhesive fixed to the support card body.
 23. Objectaccording to claim 16, wherein the object is connected to the supportcard by means of strips having a predetermined break-off line. 24.Object according to claim 23, wherein the object is attached to thestrips so as to be entirely positioned above the general top plane ofthe card.
 25. Portable electronic object having at least one face andcontact pads, tracks or electrical connectors arranged under this face,said object comprising a so-called main opening allowing the contactpads or main connectors to be accessed through this opening in adirection (J), further comprising at least one window made in said faceso as to make the contact pads, tracks or main electrical connectorsused for electrical transfer accessible through the window and in adirection other than the direction (J).
 26. Portable electronic objectaccording to claim 25, wherein said object comprises a PCMCIA card. 27.Object according to claim 25, constituting a USB key comprising ahandling body and a connector extending as an extension of the body,said connector having a band surrounding linear contact pads, whereinsaid window is located in the band facing the electrical contact pads.